Apparatus for forming coreless rolls of fibrous wool ribbon



April 17, 1962 J; G. RZESzUTKO ETAL 3,029,493

APPARATUS FOR FORMING CORELESS ROLLS OF' FIBROUS WOOL RIBBON Filed Sept.29, 1959 6 Sheets-Sheet 1 L\ T ST S J. G. RzEszuTKo ETAL April 17, 19623,029,493

APPARATUS FOR FORMING coRELEss RoLLs oF FIBRoUs wooL RIBBON Filed sept.29, 1959 6 Sheets-Sheet 2 kw ww April 17, 1962 J. G. RzEszUTKo ETAL3,029,493

APPARATUS FOR FORMING CORELESS ROLLS OF' FIBROUS WOOL RIBBON 6Sheets-Sheet 3 Filed Sept. 29, 1959 IHHHIIIIIII J. G. RzEszUTKo ETAL3,029,493

April 17, 1962 APPARATUS FOR FORMING CORELESS ROLLS OF FIBROUS WOOLRIBBON 6 Sheets-Sheet 4 Filed Sept. 29, 1959 April 17 1962 J. G.RzEszuTKo ETAL APPARATUS FOR FORMING CORELESS ROLLS OF FIBROUSWOOL'RIBBON 6 Sheets-Sheet 5 Filed Sept. 29, 1959 n @y um April 17,-1962J. G. RzEszuTKo ETAL 3,029,493

APPARATUS FOR FORMING coRELEss RoLLs oF FIBRoUs woor. RIBBON Filed Sept.29, 1959 6 Sheets-Sheet 6 www@ 3,029,493 Patented Apr. 17,v 1962 3029,493 APPARATUS FR FRMlNG COREL-ESS ROLLS F FEBROUS WQDL RIBB'ONJoseph G. Rzeszutlro and Frank P. Lawler, Chicago, lll.,

assignors to .iarnes H. Rhodes it Company, Chicago,

lll., a corporation or' Iliinois Filed Sept. 29, 1959, Ser. No. 843,283"l Claims. (Cl. 29-1) The present invention relates to apparatus forforming coreless rolls of fibrous material, particularly steel woolribbon. An earlier and different apparatus for performing this operationis disclosed in expired US. Patent No. 1,968,310 to Peterson.

For convenience, the present invention is described herein as anapparatus for forming coreless rolls of steel wool ribbon. It is to beunderstood, however, that the apparatus also has utility for rolling anykind or" fibrous material such as bronze wool, plastic wool, etc.

An important object of the invention is to provide a new and improvedapparatus for forming coreless rolls of steel -wool ribbon and the likewherein the ribbon of steel wool may be directed from a steel woolproducing machine directly to the apparatus which then rolls and cutsthe ribbon in a manner such that the rolls discharged from the apparatusare substantially uniform in size and weight.

Another object of the invention is to provide a new and improvedapparatus of the character described which is mobile and which may bemoved between various librous wool producing machines which are turningout dilerent grades of tibrous wool ribbon.

A more detailed object of the invention is to provide a new and improvedapparatus of the character described wherein a ribbon of steel wool orthe like is advanced onto a rst conveyor for movement beneath a dragdevice which turns up the end of the ribbon and initiates the formationof the roll thereof after which the initially formed roll is advanced bythe first conveyor beneath a second conveyor moving in the oppositedirection at a somewhat lesser rate of speed whereby the ditierentialaction of the two conveyors efects continued formation of the roll ofribbon while simultaneously advancing the roll toward the discharge endof the apparatus.

A further object of the invention is to provide a new and improvedapparatus of the character described wherein a timer-actuated cutter isprovided for cutting the ribbon of fibrous wool at uniform intervalswhereby the rolls of ribbon discharged from the apparatus aresubstantially uniform in size and weight.

Another important object of the invention is to provide a new andimproved apparatus of the character described wherein the drag device,which because it is preferably forme-d partially of felt and issubjected to wear by the steel wool ribbon or the like, is easily andquickly replaceable without shutting down the apparatus.

Another object of the invention is to provide a new and improvedapparatus of the character described which is readily adjustable wherebyto permit the formation of rolls of fibrous wool ribbon of differentsizes, of diderent weights, and of different grades and material.

Further objects or the invention are to provide apparatus of thecharacter described which is economical to fabricate, sturdy, andadaptable for various conditions and requirements, which is simple andefcient in operation, and which requires little maintenance.

Certain other obiects of the invention will, in part, be obvious, andwill in part appear hereinafter.

For a more complete understanding of the nature and l scope of theinvention reference may now be had to the accompanying drawings wherein:

FIG. l is a side elevational view of a preferred form of the invention;

FIG. 2 is an enlarged cross along the line 2 2 of FIG. 1;

FIG. 3 is an enlarged cross along the line 3 3 of FIG. 1;

FIG. 4 is an enlarged cross along the line 4 4 of FIG. I;

FIG. 5 is an enlarged cross along the line 5 5 of FIG. l;

FIG, 6 is an enlarged cross along rthe line 6 6 of FIG. l;

FiG. 7 is an enlarged right roller assembly taken generally FIG. 1;

FlG. 8 is an enlarged longitudinal vertical section of the rollinitiating portion of the apparatus shown in FIG. l and illustrating inbroken lines the formation of a coreless roll of steel wool ribbon;

FIG. 9 is a cross section taken generally along the line 9 9 of FIG. 8;

FIG. l0 is an enlarged side elevational view of the rotary cutterassembly shown in FIG. l;

section taken generally sec ion taken generally section taken generallysection taken generally section taken generally end view of the pinchalong the line 7 7 of FIG. l1 is a right end elevational View, partiallyin vertical section, of the cutter assembly shown in FIG. l0 with therotary knife blade shown rotated toits uppermost position;

FIG. 12 is an end elevation View of the cutter assemly brake takengenerally along the line l2 12 of FIG. 1l;

FIG. 13 is a reduced scale top plan View of the upper pinch rollerillustrated in FIG. 7.

The embodiment of the invention illustrated in FIG. 1 comprises a Seriesof basic structures, namely, a supporting base 10, a lower conveyor 11,an upper conveyor 12, a drag device 13 for initiating the formation ofthe coreless rolls of steel wool ribbon or the like, a pinch rollerassembly 1d for pulling a ribbon of steel wool into the apparatus, and arotary knife assembly 15 for cutting the ribbon of steel wool. Suitabledrive and control means are also provided.

The supporting base 1u is an elongated, generally rectangular open-frametype structure including a series of lower, horizontally disposedsupport members 18, a series of upper horizontally disposed supportmembers 19, a pair of vertically extending end support members Z at oneend thereof, a pair of vertically extending end support members 21 atthe opposite end thereof, and a series of inclined brace members 22. Thepair of vertical end members 2li extend somewhat above the upper supportmembers 1.9 and the pair of vertical end members 21 extend a substantialdistance above the upper support members 19 for purposes which will beself-evident hereinafter. A pair of vertical support plates 23 aresecured to the upper ends of the end support members 21 and extend in adirection away from the supporting base .10 whereby to support the pinchroller assembly 14 and the rotary knife assembly 15 therebetween. Thesupporting base lill is supported on a series of pivotable casters`Z-iwhereby the apparatus is mobile and may be readily moved betweenvarious steel wool machines producing different grades of steel woolribbon, between diierent ribbon stations of the same machine, or to aposition adjacent a previously manufactured stock of steel wool ribbon.a

A variable speed drive motor 25, whose speed is readily adjustable bymeans of a hand crank 26, is centrally supported within the open framesupporting base 10 on `a plate member 27 which is suitably securedbetween a pair of the lower support members 18. The motor 25 is providedwith a drive shaft 2S which carries a small sprocket 29. A pair of sideplates Sti are secured between the lower and upper support members 18and 19 of the supporting base adjacent the vertical end support members21. A jackshaft 31 is rotatably supported by a pair of bearing blocks 32each of which is secured to one of the side plates 30. The jackshaft 31carries a large sprocket 33 which is driven by an endless chain 34 whichpasses around the small sprocket 29 on the drive shaft 28 of the motor25. The jackshaft 31 also carries a small sprocket 35.

The lower conveyor 11 (FIGS. l-4) includes a frame 40 which ischaracterized by an elongated tlat plate member 41 having elongatedangle members attached thereto in a manner to provide depending sideanges 42. The lower conveyor frame 4th has one end pivotably mountedbetween the vertical end support members 21 of the supporting base 10somewhat above the upper horizontal support members 19 thereof. Asuitable pivot pin 43 extends between the vertical support members 21and the side flanges 42 of the lower conveyor frame 4t). The oppositeend ofthe lower conveyor frame 4t) is adjustably supported at a pointspaced a substantial distance in from the end thereof between thevertical end support members of the supporting base 10 whereby asubstantial portion of the lower conveyor 11 projects beyond thevertical end supports 20 of the supporting base 10. In the embodimentshown in FIG. 1, approximately one-third of the length of the lowerconveyor 11 projects beyond the end of the supporting base 1t). Asuitable support pin 44 is adapted to be inserted through the sideflanges 42 of the lower conveyor frame 40 and through one pair of aseries of vertically spaced pairs of openings formed in the vertical endsupport members 29 whereby the lower conveyor frame tti may be supportedin a horizonztal position or in positions inclined slightly above orbelow the horizontal position. In FIG. l, the lower conveyor frame 40 issupported with the projecting end thereof inclined slightly upwardlyfrom the pivotably connected end thereof.

Referring now to FIGS. 1 and 2, a pair of support plates 59 depend fromthe side flanges 42 of the lower conveyor frame 4t) at the end thereofadjacent the pivot pin 43. A pair of bearing blocks 51 are mounted oneon each of the plates 5G and a jackshaft 52. is rotatably supportedtherein. A large sprocket 53 is keyed to the jackshaft 52 and is drivenby means of an endless chain 54 which extends around the sprocket 35 onthe jackshaft 31. A pulley 55 and sprockets 56 and 57 are also keyed tothe jackshaft 52. The radius of the pulley 55 is substantially equal tothe distance between the aids of the jackshatt 52 and the upper surfaceof the horizontal plate portion 41 of the lower conveyor frame 49. rIhehorizontal plate portion 41 of the lower conveyor frame di? terminatesat a point to the left of the axis of the jackshaft 52 (as viewed inFIG. l of the drawings) for a purpose which will be obvious hereinafter.

As best illustrated in FIGS. 1 and 3, a pair of support plates 60 dependfrom the projecting end of the lower conveyor frame 40 and includeportions extending somewhat forwardly thereof. The plates 6G eachsupport a bearing block 61 between which extends a freely rotatablejackshaft 62. A pulley 63, which is the same size as the pulley 55, iskeyed to the jackshaft 62. The forwardly extending portions of themounting plates 69 are each provided with an elongated slot 64 wherebythe jackshaft 62 may be adjustably shifted relative to the plates 69 ina well known manner by means of adjusting screws 65 whereby to adjustthe center-to-center distance between the pulleys 55 and 63.

An endless conveyor belt 66 which may be formed of any suitable beltmaterial extends around the pulleys 55 and 63. The belt 66 isapproximately the same width as the ribbon of steel wool to be rolledand is provided with a plurality of uniformly spaced transverse orlaterally extending cleats 67 which may be either riveted or sewn ontothe belt or even formed integrally therewith. During operation of thedrive motor 25, the pulley 55 is driven in a direction such that theupper run of the belt 66 moves toward the projecting end of the lowerconveyor `frame 4ta which is the discharge end of the apparatus.

A pair of sidewalls or guideways 70 extend upwardly from the horizontalplate portion 41 of the lower conveyor frame 40 with each being disposedclosely adjacent to a margin or edge of the belt 66. The sidewalls 70extend generally the whole length of the lower conveyor frame 46 withtheir height increasing gradually toward the discharge end of theapparatus. Each sidewall 70 is suitably braced by an attached anglebracket member 71 which is secured to the Hat plate member 41 of thelower conveyor `frame 40.

The upper conveyor 12 is supported directly on the lower conveyor frame40 as will now be described. The upper conveyor 12 includes a frame 75which is characterized by a pair of elongated, vertically disposed platemembers 76 which are spaced apart in parallel alignment by two sets oftransverely extending brace members 77. The two sets of brace members 77are located near oppo- Y site ends of the upper conveyor frame 75 andadjacent the upper portions of the plate members 76.

One end of the upper conveyor frame 75 is pivotably mounted (FIGS. 1 and4) between a pair of upright ear members 60 which have dat base portionssecured to the ilat plate member 41 of the lower conveyor frame 40outwardly of the sidewalls 70. 1f necessary, spacer bars 79 may Abedisposed between the plate 41 and the base portions of the ear members80. In the embodiment illustrated in FIG. l, the ear members 80 arelocated approximately in vertical alignment with the longitudinalmidpoint of the mobile supporting base 10. Adjacent ends of theelongated plate members 76 of the upper conveyor frame 75 are eachsecured to one of a pair of bearing blocks S1 each of which is rotatablymounted in a bore formed in one of the ear members 80. A jackshaft 82 isrotatably supported by the two bearing blocks 81 and has a pulley 83 anda sprocket 84 keyed thereto. An endless chain 85 extends around thesprocket 4 and the sprocket 56 carried on the shaft 52 whereby thepulley 33 is driven counter-clockwise (as viewed in FIG. l) when thedrive motor 25 is operated. The arrangement is such that the perimeterof the pulley 83 rotates a relatively short distance above the upper runof the cleated lower conveyor belt 66.

The opposite ends of the spaced apart elongated plate members 76 of theupper conveyor frame 75 are provided with projecting tongues each ofwhich supports a bearing lock 86. A jackshaft 87 is rotatably supportedby the two bearing blocks 86 and has a pulley 88 keyed thereto. Theprojecting tongues of the plate members 76 are provided with elongatedslots 89 to permit adjustment of the jackshaft 87 relative to thetongues by means of adjusting screws 96 whereby the center-to-centerdistance between the pulleys 83 and 8S may be readily adjusted in awell-known manner. An endless conveyor belt 91 extends around thepulleys 83 and 38. During operation of the drive motor 25, the pulley 83is driven in a direction such that the lower run of the upper conveyorbelt 91 moves in a direction away from the discharge end of theapparatus and opposite to the movement of the upper run of the lowerconveyor belt 66 disposed therebelow.

In the embodiment of the invention shown in the drawings, the pulleys 83and 88 of the upper conveyor 12 are the same size as the pulleys 55 and63 of the lower con veyor 11. For a reason which will be fully explainedhereinafter the sprockets 56 and 84 are selected such that the ratio ofthe speed of movement of the upper conveyor belt 91 to the speed of thelower conveyor belt 66 is in the order of 8:10.

Adjustable support means are provided for the upper U conveyor 12adjacent the end thereof carrying the pulley S8 whereby the end of theupper conveyor 12 may be pivotably raised and lowered relative to thelower conveyor 11. -The apparatus is therefore readily adaptable forforming coreless rolls of steel wool ribbon of Various diameters. Theadjustable support means, as best illustrated in FIGS. l and 6,comprises a pair of upright posts of the upper conveyor frame 75 and aresecured at their lower ends to the flat plate 41 of the lower conveyorframe 41D. A cross bar 96 is secured to the upper ends of the two posts95 and is provided adjacent one end thereof with a pair of spaced apartupright members 97 and 98. A horizontally disposed shaft 99 is rotatablysupported in aligned bores formed in the upright members 97 and 9S andhas a handle 11)@ pinned to one end thereof and a ruiter or bevel gear101 pinned to the opposite end thereof. A mating miter or bevel gear1132 is rotatably supported on the `cross bar '96 in meshing engagementwith the gear 161 and with its axis in vertical alignment with thelateral midpoint of the upper conveyor 12. A threaded rod 1113 extendsvertically through the gear 102, which has an internally threaded bore130.1 therein, and downwardly through a bore 1115 formed in the crossbar 96.

A bifurcated or U-shaped member 106 is secured to the lower end of thethreaded rod 193 and has a pair of laterally spaced arms 197 whichextend downwardly alongside the spaced apart elongated plate members 76of the upper conveyor frame 75. A pivot pin 108 extends through the arms107 of the bifurcated member 106 and through the spaced apart members 76of the upper conveyor frame 75 whereby the end of the upper conveyor 12adjacent the pulley S8 is supported by the threaded rod 163 which is inturn adjustably supported by the gear 102.

When the handle 1110 is rotated, the gear 102 is rotated*v through itsmeshing engagement with the gear 101 whereby the threaded rod 103 iseither adjustably moved upwardly or downwardly relative to the gear 102to either raise or lower the end of the upper conveyor 12 adjacent thedischarge end of the apparatus. angle between the upper conveyor 12 andthe lower conveyor 11 is approximately 7 which has been found to be asuitable angle for forming rolls of steel wool ribbon approximately 8 indiameter.

An adjustable elongated backing member or shoe 112 is provided forengagement with the upper surface of the lower run of the upper conveyorbelt 91. The shoe 112 is supported adjacent its opposite ends by a pairof rods 113 which extend `upwardly through bores formed in thetransversely extending ybrace members 77 of the upper conveyor frame 75.The upper ends of the rods 113 are threadedly engaged in nuts 114 whichare rotatably confined between the uppermost transversely extendingbrace members '77 and inverted U-shaped members 115 mounted thereon. Byspinning the nuts 114, the rods 113 may be raised or lowered to decreaseor increase, respectively, the compressive and frictional forces exertedIby the lower run of the upper conveyor belt 91 on the rolls of steelwool ribbon being formed between the lower belt 66 and the upper belt91. The formation of the rolls of steel wool ribbon will be fullydescribed hereinafter.

As best illustrated in FIG. 6, the hat plate member 41 or" the lowerconveyor frame 411, the sidewalls 76 and the shoe 112 define a rollingchannel or tunnel 119 which is generally rectangular in cross sectionwith the height thereof increasing progressively toward the dischargeend of the apparatus. The upper run of the lower conveyor belt 66 ismovable along the lower surface of the rolling `channel 119 toward thedischarge end 0f the apparatus and the lower run of the upper conveyorbelt 91 is movable adjacent the underside of the upper surface of therolling channel 119 in a direction away from the discharge end of theapparatus.

The pinch roller assembly 14, which is adapted to advance a ribbon ofsteel `wool from either a previously In FIGS. 1 and 8, the l' '95 whichare spaced in lateral alignment at opposite sides produced supplythereof or directly from a steel wool producing machine onto the lowerconveyor belt 66, is best illustrated in FIGS. l, 7 and 13. The assembly14 includes a pair of pinch rollers 4120 and 121 disposed one above theother with the lower roller being driven and the upper roller 121 beingfreely rotatable. The driven roller 120 is mounted on a jackshaft 122which is rotatably supported by a pair of bearing blocks 123 each ofwhich is secured to one of the supporting plates 23 mounted on the upperend of the vertical end supports 21 of the supporting base 21);Asprocket 124 and a Spur gear 125 are keyed to the jackshaft 122. Toprovide a drive for the lower pinch roller 120 (counter-clockwise asviewed in FIG. 1) an endless chain 126 extends around the sprocket 124and around the sprocket 57 keyed to the jackshaft 52 upon which shaftthe pulley 55 is mounted.

The upper pinch roller 121 is carried on a jackshaft 127 which isrotatably supported by a pair of bearing blocks 128 each of which ismounted on one of a pair of arms 129. Adjacent ends of the arms 129 areeach pivotably mounted, as at 1311 in FIG. 13, on one of the supportingplates 23 whereby the upper pinch roller 121 is held against the lowerpinch roller 120, or a ribbon of steel Wool disposed therebetween, byits own weight. The opposite ends of the arms 129 are interconnected bya rod 131 which is provided with a pair of vertically extending slidablyadjustable guide members 132. The guide members 132 center the ribbon ofsteel wool being pulled into the apparatus by the pinch rollers 120 and121. To start a ribbon of steel wool through the apparatus, the upperroller 121 is manually lifted after which the forward end of Ithe ribbonof steel wool is inserted between the guide members i132 and over thelower pinch roller 120 after which the upper pinch roller 121 isreleased for contacting engagement with the upper surface of the ribbonof steel wool. During operation of the drive motor 25, the two pinchrollers 129 and 121 co-act in a well-known manner to pull the ribbon ofsteel wool into the apparatus. In the embodiment of the invention shownin the drawings, the axes of the two pinch rollers 120 and 121 are invertical alignment. As various grades of steel wool may be processed bythe apparatus disclosed herein, the arms 129 are provided with elongatedslots (not shown) whereby to permit shifting the axis of the upperroller 121 relative to the axis of the lower roller 120. This adjustmentpermits the angle at which the ribbon of steel wool leaves the rollerassembly 14 `to be retained relatively uniform ldespite the variousgrades of steel wool ribbon being pulled into the apparatus by the pinchrollers 120 and 121. A channel-shaped trough or chute 133 may beprovided to direct the ribbon of steel wool from the pinch rollerassembly 14 onto the upper run of the lower belt conveyor 1'1 at a pointthereon located between the pulley 55 thereof and the pulley 83 of theupper belt conveyor 12.

After the ribbon of steel wool is directed onto the upper run of thebelt 66, it is advanced by the cleats 67 thereon toward the drag device'13 which is adapted to initiate the formation of a coreless roll ofsteel wool ribbon. The drag device 13 and the initiation of theformation of a coreless roll of steel wool ribbon are best'illustratedin FIGS. 8 and 9. The drag device 13 includes elements 'Which'are moreor less permanently assembled in the apparatus and a readily replaceablepickup cartridge 139. Briefly, the permanently assembled'elementsinclude a pivotably mounted upper `guide block 141i and a rigidlymounted anchor block 145.

The upper guide block is pivotably mounted adjacent the pulley 83 of theupper conveyor 12 on a pivot pin 141 which extends between the sidewalls70 and the angle brackets 71. An elongated upper guide member 142 whichis formed of spring material is secured at one end to the underside ofthe guide block 140 and is curved in a manner such that the other endthereof extends beneath the pulley 83 and a considerable distance beyondthe block 140. As the pivot pin 1411 is disposed between the projectingend of the guide member 142 and the center of mass of the block 140, theprojecting end of the guide member `142 is normally pivoted upwardly andinto contacting engagement with the lower run of the upper conveyor belt91, the guide member `142 being approximately the same width as the belt91. 1f desirable, a counterweight or spring means may be associated withthe block 140 to insure this engagement between the guide member 142 andthe belt 91. The purpose for this engagement between the end of theguide member 142 and Ithe belt 91 will be fully explained hereinafter.By removing the pivot pin 141, the guide block 140 and the guide member142 may be removed from the apparatus if this should appear necessary ordesirable.

The anchor block 145 is rigidly mounted between the sidewalls 70 on apair of pins 146 which extend therebetween. The anchor block 145 ismounted at a predetermined angle to a plane which is disposed normallyto and transversely of the lower conveyor 11. In the embodiment shown inthe drawings an angle of approximately 12 has been found to be suitable.An anchor pin 147 is permanently mounted in the anchor block 145 and itprojects from the outer face thereof at right angles thereto whereby toprovide a mounting means for the replaceable pickup cartridge `139.

The pickup cartridge 139, as best shown in FIGS. 8 and 9, comprises anupwardly opening U-shaped member 150 the width of which is somewhat lessthan the distance between the sidewalls 7i), a block 151 which issecured between the ends of the spaced apart arms 149 of the member `150and spaced from the closed end 143 thereof, and a clamping bar 152between the arms 149 which is slidable between the block 151 and theclosed end 14S of the member 150. The block 151 is provided with a pairof adjustable clamping bolts 153 the ends of which are engageable inrecesses formed in the clamping block 152 whereby a series of drag orpickup members may be clamped between the clamping bar 152 and theclosed end 148 of the member 150. The block 151 is provided with acentral bore 154 whereby the pickup cartridge 139 may be fitted on theanchor pin v147 or removed therefrom very rapidly. In the pickupcartridge 139 shown in FIGS. 8 and 9, the drag members include a lowerfelt pad or tongue 157, a tongue 15S formed of spring metal whichoverlies the felt tongue 157 and normally biasesv the end of itdownwardly into contact with the upper run of the lower conveyor belt66, and a substantially longer felt pad or tongue 159 which overlies thespring metal tongue 15S. The end of the felt tongue 159 should notextend beyond the end of the upper guide member 1.42.

As the forward end of a ribbon of steel wool is advanced toward the dragdevice 13 by the lower conveyor belt 66, it is engaged by the lower feltpad 157 which picks up and turns back the end of the ribbon and thusinitiates the formation of a coreless roll of steel wool ribbon. Thefelt pad 157 extends away from the U-shaped member 150 and the anchorblock 145 at generally right angles thereto whereby the end of `the feltpad 157 is normally disposed at an angle of approximately 12 to theupper run of the lower conveyor belt 66. Although this angle has beenfound to provide an effective ribbon-pickup characteristic for theembodiment illustrated and described herein, this angle may be varied tosuit other conditions. As the initially formed roll of steel wool ribbonis advanced through the apparatus the frictional engagement of the feltpads 157 and 159 with the upper portion thereof effects continuedformation of the roll. As the roll of ribbon increases in size the feltpad 159 is raised upwardly against the guide member 142. The progressiveformation of a single roll of ribbon is illustrated in broken lines inFIG. 8. When the roll of ribbon passes the end of the upper guide member142, the upper portion thereof is frictionally engaged by the lower runof the upper conveyor belt 9-1 which is moving in a direction oppositeto the forward motion of the roll. At this point, the action ofthe upperconveyor belt 91 would tend to pull fragments of the steel wool over theend of the guide member 142 and interfere with the proper formation ofthe roll if the end of the upper guide member 142 were not held inengagement with the lower run of the upper conveyor belt 91 ashereinbefore described. As the upper conveyor belt 91 is moving at aslower rate of speed than the lower conveyor belt 66, the progressivelygrowing roll of steel wool ribbon will have a continuous forward motiontoward the discharge end of the apparatus at a speed substantially lessthan the speed of the lower conveyor belt 66. As before stated herein,it has been found that the speed of the upper belt 91 should preferablybe approximately of the speed of the lower belt 66.

The differential action of the two belts 66 and 91 on the roll of steelwool ribbon is highly effective for continued formation of the roll asthe roll is moved toward the discharge end of the apparatus and permitsthe formation of a sizable roll during a relatively short forward motionof the roll itself. This advantageous feature negates the apparatusbeing so long that it takes up valuable space and is unwieldy to shiftfrom one location to another. Inasmuch as, the upper conveyor belt 91exerts an opposite frictional force on the upper portion of the rollbeing formed there is a more rapid roll formation between the belts 66and 91 than between the felt pads 157 and 159 and the belt 66 as thepads merely exert a static force on the upper portion of the roll beingformed. The backing shoe 112 for the lower run of the upper conveyorbelt 91 may be adjusted as previously described herein to vary theformation of the roll by varying the compression and frictional forcesexerted by the belt 91 on the roll.

During the later part of the formation of the roll between the belts 66and 91 some tension will develop in the ribbon of steel wool between theroll and the pinch rollers and 121. To prevent the ribbon of steel woolfrom being pulled across the relatively sharp edge of the pickupcartridge 139 when this occurs, a guide roller 161 is mounted betweenythe sidewalls 70 to the right and below the pickup cartridge 139 (asviewed in FIG. l) with the ribbon of steel wool being adapted to passunder the guide roller 161. The fact that there is some tensiondeveloped in the ribbon of steel wool during the latter portion of theformation of the roll is very important as will be described hereinafterin detail.

The arrangement and selection of the drag or pickup members for thepickup cartridge 139 may be widely varied for various conditions andmaterials being rolled. For instance, the felt pad 157 and the springtongue 15S could be replaced by a single felt pad of greater thicknessthe weight of which would be sufficient to hold the end of it againstthe belt 66 and insure a proper pickup of the end of the ribbon of steelwool. The pickup tongues may also be formed of various other materials,such as rubber-like material and certain plastics, to suit differentinherent characteristics of various materials being rolled.

When felt is used to form the drag or pickup members, it is obvious thatthere will be some wearing of the felt due to the frictional engagementthereof with the steel wool. With the replaceable pickup cartridge 139disclosed herein, it is a simple matter to remove the cartridge from theanchor pin 147 when the felt tongues thereof have become worn, duringthe period the roll is being formed between the belts 66 and 91, andreplace it with a cartridge having new felt tongues clamped therein.With the structural arrangement disclosed herein, this cartridgereplacement can be accomplished in a matter of seconds and withoutshutting down the apparatus. Obviously, this is a very importantadvantage, particularly during periods of heavy demand for a continuousproduction of rolls of steel wool ribbon.

Provision is also made for cutting the ribbon of steel wool at uniformintervals whereby the completed rolls discharged from the apparatus willbe substantially uniform in weight. As shown in FIG. 1, the rotary knifeassembly 15 is disposed adjacent the pinch roller assembly 14. Thedetails of the rotary knife assembly \15 are best shown in FIGS. 10, 1land 12. A jackshaft 165 is rotatably supported by a pair of bearingblocks 166 each of which is secured to one of the supporting plates 23.A pair of spaced apart arms 167 are rotatably mounted at adjacent'endsthereof on the jackshaft 165 by means of ball bearings .168 with eacharm `167 being disposed adjacent fthe inner surface of one of thesupport plates 23. A knife blade 169 having a cutting edge 170 issecured between the opposite ends of the arms 167. A pair of linkagearrangements are provided for adjusting the position of the knife blade169 with each arrangement being characterized by a vertically adjustablelink member 171 which is carried on the outer surface of one of thesupporting plates 23 and by a pin 172 which extends transversely betweenthe upper end of the link member 171 and one of the arms 167intermediate the ends thereof. The pins 172 extend through verticallyelongated slots 173 formed in each of the supporting plates 23. Byadjusting the link members 171 in a vertical direction the arms 167 arepivoted about the jackshaft 165 whereby to position the knife blade i169relative thereto. The 'knife blade 169 should be positioned so that theribbon of steel wool coming from the pinch roller assembly 14 passesover the cutting edge 170 thereof but preferably not in engagementtherewith so as to prevent the steel wool from dulling the cutting edge`170. This blade adjustment feature is provided because it has beenfound that different grades of steel wool leave the pinch rollerassembly 14 at `different angles at any given speed Of the driven pinchroller 120. Once the knife blade 169 has been properly adjusted for aparticular grade of steel wool and a particular ribbon feed rate, it isnormally retained in its adjusted position. Hereafter, therefore, theknife blade 169 will be referred to as the stationary knife blade.

As best illustrated in FG. 1l, a pair of rotary knife wheels 175 arekeyed to the jackshaft 165 with each of the wheels 175 being disposedadjacent the inner surface 0f one of the stationary blade supportingarms 167. A rotary knife blade 176 having a cutting edge 177 is securedin aligned notches formed in the perimeters of the two wheels 175 andextends therebetween. The normal stopped position of the rotary knifeblade 176, as illustrated in FIG. 10, is approximately 180 away from thestationary knife blade 169. The rotary blade 176 is adapted to beperiodically rotated past the stationary knife blade 169 in a clockwisedirection (as viewed in FIG. 10) whereby to cut the ribbon of steelwool.

.An adjustable friction brake 19t) which is disposed adjacent one end ofthe jackshaft 165 exerts a continual braking action thereon and tends toprevent rotation of the jackshaft 165. The brake 19t) is mounted on oneof the supporting plates 23 by means of an angular bracket 191 andincludes a brake drum 192 which is keyed to the jackshaft 165, a brakelining 193 disposed about the brake drum 192, and an adjustable clampingmember 194 which is disposed about the brake lining 193, The brakingaction of the brake 19t? is adjustable in a well-known manner by aspring-tightening device 195 associated with the clamping member 194.

A single revolution clutch '180 of a well-known type, such as thesingle-revolution clutch which is fully disclosed in expired DickensPatent No. 2,140,737 and is commercially available from The HilliardCorporation of Elmira, New York, is carried on a reduced diameterportion of the jackshaft 165 and has a spur gear 181 keyed to oneportion thereof. The spur gear 181 meshes with the spur gear 125 carriedon the jackshaft 122 whereby the one portion of the clutch 18) rotatescontinuously in a clockwise direction (as viewed in FIGS. l and l0)during the operation of the drive motor 25. A cam 182l having a radialshoulder 133 is associated with the clutch 180.

10 An arm 134 which is pivotably mounted intermediate its ends on a pin185 has an upper end 136 which is engageable with the radial shoulder183 of the clutch cam 182. When the end 186 of the arm 184 is inengagement with the radial shoulder 183 of the clutch cam 132, theclutch 180 is disengaged from the jackshaft 165 and the rotary knifeblade 176 is retained in its normally stopped position by the brake 19d.A spring 16,7' is connected between an anchor bracket 188 and theopposite lower end of the Yarm 164 whereby to normally urge the end 186of the arm 18a into its clutch disengaging position in contact with theradial shoulder 183 of the cam 182.

The lower end of the arm 184 is pivotably connected to a plunger 2% of asolenoid 2111. When the solenoid 201 is energized, the plunger 26d ismoved inwardly of the core thereof. This inward movement of the plunger20d pivots the upper end 186 of the arm 184- out of engagement with theradial shoulder 183 of the clutch cam 132 whereby to positively engagethe clutch 180 with the jackshaft and cause clockwise rotation of therotary knife blade 176 past the stationary knife blade 169, therebycutting the ribbon of steel wool. An eccentric 2414 which is associatedwith the clutch 1811 is rotatable only during rotation of the jackshaft1.65. The eccentric 2194 is adapted upon rotation thereof to actuate aplunger 2115 of a limit switch 206 before the completion of a fullrevolution of the jackshaft 165. Actuation of the limit switch Z116 bythe eccentric 2114 deenergizes the solenoid 201 thereby permitting thespring 187 to pivot the arm 184 in a direction such that the upper end1&3 thereof will be in position for engagement with the radial flange183 of the clutch cam 182 whereby to disengage the clutch 130 from thejackshaft '165. The rotary knife blade 176 may then be brought to a stopby the brake 190 after a single revolution thereof and until thesolenoid 201 is again energized.

The gearing 12S-131 is selected so that the rotary knife blade 176 isrotated past the stationary knife blade 169 at a relatively fast rate ofspeed so that the newly cut forward end of the ribbon of steel wool willnot jam up against the rotary knife blade 176. As before describedherein, the ribbon of steel wool is under some tension at the time therotary knife blade 176 is rotated through its cutting stroke whereby thetrailing end of the ribbon in the process of being rolled between thebelts 66 and 91 will jump somewhat ahead of the newly cut forward end ofthe ribbon of Steel wool. rl`his insures that there will be a gapbetween the trailing end of the ribbon being rolled and the forward endof the ribbon directed onto the upper run of the lower conveyor belt 66.Without such a gap, the lower felt tongue 157 may not drop down intoengagement with the belt 66 which is its position for picking up andturning back the forward end of the following ribbon of steel woolwhereby to initiate the formation of the next roll of steel wool ribbon.

r[he solenoid 2111 is adapted to be energized to engage the clutch withthe jackshaft 165, as previously described herein, by an adjustabletimer 210 which may be mounted on the lower conveyor frame 40 in aposition convenient to the operator of the apparatus. The timer 211) isof a type well-known in the art and commercially available. As the timerstructure comprises no part of the invention it will not be describedherein. By adjusting the timer 210, the operator can control the lengthof ribbon in the rolls and thus the weight of the rolls of steel woolribbon discharged from the apparatus. Once the timer 210 has beenadjusted as desired, the rolls of steel Wool ribbon discharged from theapparatus will be substantially uniform in weight and size.

The operation of the apparatus is relatively simple. After the upperconveyor 12v has been adjusted to a desired angle relative to the lowerconveyor 11 and the timer 210 has been set to provide a roll of steelwool ribbon of a desired weight and size for vthe selected speed ofoperation of the apparatus, the forward end of the ribbon of steel woolis inserted between the two pinch rollers 120 and 121. The drive motor25 is then started and adjusted for the desired speed of operation. Ifthe steel wool ribbon being rolled is being taken from a stock ofpreviously manufactured steel wool, the speed of the drive motor 25 maybe set for any speed within its range of operation. However, if theribbon of steel wool being rolled is coming directly from a steel woolproducing machine, the speed of the drive motor 25 should besynchronized with the output of the steel Wool producing machine so thatthere will be just a slight dip in the ribbon between the steel woolproducing machine and the pinch roller assembly 14. In this situation ithas been found that the speed of the lower conveyor belt 66 should beapproximately the same as the output speed of the ribbon of steel woolcoming from the steel wool producing machine, the speed of the upperconveyor belt 31 being approximately 80% thereof.

The ribbon of steel wool is thus pulled between the pinch rollers 129and 121, over the stationary knife blade 169 and down the chute 133 ontothe upper run of the lower conveyor belt 66. The forward end of theribbon of steel wool is then moved toward and beneath the drag device 13`whereby the forward end is picked up and turned back upon itself toinitiate the formation of the roll of steel wool ribbon. The initiallyformed roll is moved past the drag device 13 until the upper portionthereof is frictionally engaged by the lower run of the upper conveyorbelt 9i. whereby the formation of the roll is continued while the rollcontinues its forward motion toward the discharge end of the apparatusat a rate of movement which is relatively slow compared to the rate ofmovement of the upper run of the lower conveyor belt 66. During theformation of the roll, the solenoid 201 is energized in response to asignal from the timer 210 whereby to drivingly engage the continuouslyrotating spur gear 181 with the jackshaft 165 through the clutch 180,thus causing a single revolution of the rotary knife blade 176 past thestationary knife blade 169 to cut the ribbon of steel wool.

With the drive motor 25 set at a specific setting, the length of steelWool ribbon in each roll discharged from the apparatus may be varied byadjustment of the timer 2N. This of course is a means for controllingboth the diameter and the weight of the rolls of steel wool ribbondischarged from the apparatus. Once the timer 210 has been set asdesired, the rolls of steel ribbon discharged from the apparatus will besubstantially uniform in weight and in diameter.

inasmuch as the drag members carried on the pickup cartridge 139 maybecome worn periodically as a result of their frictional engagement withthe steel wool, an important feature of the invention lies in the factthat the cartridge carrying the worn drag members may be quickly removedand replaced by a cartridge carrying new drag members in a matter ofseconds whereby there is no necessity for shutting down the apparatusduring such replacement.

As previously mentioned, the apparatus of the present invention isapplicable for forming coreless rolls of fibrous ribbon other thansteel, such as bronze for example, or even for materials other thanmetal such as plastic Wool or the like.

lt will be understood that certain changes may be made in theconstruction or arrangement of the apparatus for forming coreless rollsof steel wool ribbon and the like disclosed herein without departingfrom the spirit and scope of the invention as defined in the appendedclaims.

We claim:

l. Apparatus for forming a coreless roll of steel wool ribbon and thelike comprising, means providing an elongated roll-forming channel, saidchannel being generally rectangular in cross section and increasingprogressively in height from its entrance end toward its discharge end,a first conveyor belt having an upper run movable along the bottomsurface of said channel toward the discharge end thereof, a secondconveyor belt having a lower run movable through said channel adjacentthe underside of the upper surface thereof and toward the entrance endthereof, said upper run of said first conveyor belt and said lower runof said second conveyor belt diverging in a direction toward thedischarge end of said apparatus, and drag means separate from said firstand second conveyor belts positioned adjacent the entrance end of saidroll-forming channel and including an elongated friction member normallyengaging said upper run of said first conveyor belt, said frictionmember being frictionally engageable with the forward end of a ribbon ofsteel Wool advanced into the entrance end of said roll-forming channelon said upper run of said first conveyor belt whereby to turn theforward end of said ribbon upwardly and rearwardly to initiate theformation of a roll of ribbon, said friction member being yieldableupwardly away from said upper run of said first conveyor belt to permitthe passage of said initially formed roll end tlierebeneath and saidoppositely movable upper and lower runs of said first and secondconveyor belts, respectively, serving to engage the formed end andcontinue the rolling of the ribbon into a roll of ribbon relativelyrapidly while advancing the growing roll toward the discharge end ofsaid roll-forming channel.

2. Apparatus as recited in claim l wherein said second conveyor belt ismovable at a lesser rate of speed than said first conveyor belt wherebyto positively advance the growing roll of ribbon toward the dischargeend of said roll-forming channel during formation thereof.

3. tApparatus as recited in claim l wherein said separate drag meanscomprises a pickup cartridge having a lower felt-like tongue and anoverlying spring metal tongue inter-connected at one end of each andpositioned so that the opposite ends thereof are inclined downwardly andextend partially into the entrance end of said channel, said springmetal tongue yieldably biasing said felt-like tongue downwardly againstsaid upper run of said first conveyor belt whereby said felt-like tongueis frictionally engageable with the forward end of a ribbon of steelwool carried on said upper run of said first conveyor belt to initiatethe formation of a coreless roll of steel wool ribbon by frictionallypicking up said forward end of the ribbon of steel wool and turning itback upon itself.

4. Apparatus as recited in claim 3 having an anchor block fixedlymounted adjacent the entrance end of said roll-forming channel, ananchor pin projecting from said anchor block, and said pickup cartridgehaving a bore formed therein to permit mounting said cartridge on saidanchor pin, said cartridge being easily removable from said pin, as whensaid felt-like tongue becomes worn through frictional contact with thesteel wool, whereby it may be quickly replaced with a cartridge carryinga new felt-like tongue, said arrangement permitting said pickupcaltridge replacement to be completed in such a short period of timethat the apparatus need not be shut down.

5. Apparatus as recited in claim 3 wherein said pickup cartridge isprovided with a second felt-like tongue of greater length than saidlower felt-like tongue overlying said spring metal tongue for effectingcontinued formation of the roll of steel wool ribbon prior to engagementthereof by said upper and lower runs of said first and second conveyorbelts, respectively.

6. Apparatus as recited in claim 5 having a guide block pivotablymounted immediately forward of said pickup cartridge, and an elongatedflat guide member having one end secured to said guide block and theother end projecting beneath the lower run of said second conveyor belt,said guide member being disposed above said second felt-like tongue andprojecting slightly beyond the end thereof, the pivotable mounting ofsaid guide block being disposed between the center of mass thereof andthe projecting end of said guide member so that the projecting endportion of said guide member is normally urged upwardly intosubstantially parallel engagement with the lower run of -said secondconveyor belt whereby to prevent the upper portion of the initiallyformed roll of steel wool from being pulled back over the upper surfaceof said second felt-like tongue by the lower run of said second conveyorbelt when said roll is advanced by the upper run of said first conveyorbelt beyond the end of said second felt-like tongue and into frictioualengagement with said oppositely moving lower run of said second conveyorbelt.

7. Apparatus as recited in claim l having a pinch roller assembly foradvancing the forward end of a ribbon of steel wool onto the upper runof said first conveyor belt forwardly of the entrance end of saidrollforming channel, a stationary knife blade supported adjacent theexit from said pinch roller assembly whereby said ribbon of steel woolpasses over said stationary knife blade, a rotary knife blade,continuously operable 'l drive means for said rotary knife blade, anormally disengaged single-revolution clutch operably connected betweensaid rotary knife blade and said drive means therefor, a solenoidoperable when energized to engage said clutch whereby said rotary knifeblade is rotated past said stationary knife blade to cut said ribbon ofsteel wool, said clutch being automatically disengaged after a singlerevolution of said rotary knife blade, and an adjustable timer forenergizing said solenoid at uniform intervals whereby the rolls of steelwool ribbon discharged from said roll-forming channel will besubstantially uniform in size and weight.

References Cited in the file of this patent UNITED STATES PATENTS

